Rockwell Automation OTTO 100 V2.5 Operation And Maintenance Manual

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OTTO 100 V2.5

Operation and maintenance manual

OMM-000081-G

Publication date Nov-24

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Summary of Contents for Rockwell Automation OTTO 100 V2.5

Page 1 ENGLISH OTTO 100 V2.5 Operation and maintenance manual OMM-000081-G Publication date Nov-24...
Page 3: Table Of Contents
3.1. Included items ......................17 4. Applicable documents ......................19 5. In case of a collision ........................ 19 6. OTTO 100 V2.5 specifications ....................20 6.1. Size and weight ......................21 6.2. Speed and performance ....................21 6.3. Battery and power system ..................... 22 6.4.
Page 4 7.13. Ethernet connection ....................32 OTTO 100 V2.5 rear buttons/input/output ..............33 7.14. Circuit breakers and lock-out/tag-out ................33 8. Unboxing the OTTO 100 V2.5 ....................33 9. Basic usage ..........................35 9.1. Lock-out/tag-out ......................35 9.2. Starting up ........................36 9.3.
Page 5: Important Safety Information
OTTO 100 V2.5 1. IMPORTANT SAFETY INFORMATION The top priority of OTTO is the safety of its users. OTTO produces high power and fast-moving pieces of machinery that could cause serious injury, including death, if improperly used or maintained. Additional hazards may be identified and need to be addressed during the site-specific risk assessment.
Page 6: General Hazards
OTTO 100 V2.5 General hazards WARNING • BURN or SHOCK HAZARD! Never use this product if the enclosure or any of the connectors are broken, cracked, open, or show any other indication of damage. • SHOCK HAZARD! Always perform the lock-out/tag-out procedure at the facility or on the product before inspecting, servicing, cleaning, removing components, or opening any enclosure.
Page 7: Robot Hazards
OTTO 100 V2.5 Robot hazards WARNING • Always use level rigging when lifting or lowering the product. • IMPACT HAZARD! Never bypass the drive wheels of the AMR while on a sloped surface. • Never use OTTO products to transport people or live animals.
Page 8: Charger Hazards
OTTO 100 V2.5 CAUTION • IMPACT HAZARD! Always maintain a safe distance from an AMR in operation. An AMR being operated in manual mode should only be operated by personnel who have been trained and authorized according to the standards of the facility in which the AMR is in use.
Page 9: Hazard Labels
OTTO 100 V2.5 WARNING • FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged. • SHOCK HAZARD! Automatic chargers are powered by hazardous voltage levels. Do not touch the charge contacts when the product is in operation.
Page 10 OTTO 100 V2.5 Label Title Description Label Title Description Grounding Improper grounding of Pinching risk Keep hands and other electrical OTTO chargers can objects clear of pinch hazard result in a potential points at all times. shock risk. Keep clear of all docking robots.
Page 11: Safety Awareness
OTTO 100 V2.5 1.3. Safety awareness WARNING • IMPACT HAZARD! Always maintain a safe distance from an AMR in operation. An AMR being operated in manual mode should only be operated by personnel who have been trained and authorized according to the standards of the facility in which the AMR is in use.
Page 12: Facility Conditions
OTTO 100 V2.5 • Maintenance not outlined in the operations and maintenance manual can only be performed by OTTO- authorized personnel. Facility conditions WARNING • IMPACT HAZARD! Never bypass the drive wheels of the AMR while on a sloped surface.
Page 13: Payload Maximums And Stability
OTTO 100 V2.5 • Robots rely on LiDAR to protect personnel from crushing or collision hazards. Although rare, very reflective or very light absorbent (for example, black) material can impede the LiDAR safety systems. Avoid the use of such materials in clothing or obstacles to assist their detection by OTTO LiDAR safety systems.
Page 14: Safety System Functionality
OTTO 100 V2.5 Safety system functionality Autonomous mobile robots (AMR) move and travel differently depending on several factors including any detected obstacles, the AMR's speed, the currently occupied zone, and the AMR's current Step, Task, or Job. The AMR is equipped with LiDAR safety scanners. These safety scanners have a safety detection range that initiates response of the safety system.
Page 15: Safety Stop System
OTTO 100 V2.5 Emergency stop condition Description Physical A user pressing one of the Emergency Stop buttons on the robot Software A software-triggered emergency stop caused by a system fault or self-diagnostic tool Safety stop system Safety stops are similar to emergency stops; however, they are triggered by an object being detected inside of the pre-defined LiDAR safety field.
Page 16: Attachment Interfaces
OTTO 100 V2.5 Warnings and signage must be respected in these areas. Attachment interfaces The robot is designed to support an equipped attachment. Any attachment must interface with the robot to transmit fault signals as well as receive enable signals. The emergency stop system is configured such that both the attachment and the robot can initiate an emergency stop state, halting operations on both systems immediately.
Page 17: Revision History
December 2019 Initial release January 2020 Revised to include Supplier's Declaration of FCC Conformity April 2020 Revised to include information for the OTTO 100 V2.5 AMR, disposal of the robot, and expanded safety documentation May 2020 Various updates June 2020...
Page 18 OTTO 100 V2.5 • OTTO safety guide IMPORTANT No field modifications of the AMR that influence the performance or safety of the AMR are permitted. This includes, but is not exclusive to, modifications that affect the physical size, mass, or floor traction of the AMR. No modifications may be carried out that affect the integrated sensors or internal electronics.
Page 19: Applicable Documents
OTTO 100 Fast Charger operation and maintenance manual OMM-000037 OTTO 100 Manual Charger operation and maintenance manual Staging Cart operation and maintenance manual OMM-000074 OTTO 100 V2.5 stability and center of gravity ICD-000111 Standard OTTO 100 V2.5 safety configuration 017814 5. In case of a collision Cease operation Stop the AMR by pressing an Emergency Stop button on the AMR or an equipped attachment.
Page 20: Otto 100 V2.5 Specifications
Confirm there are no exceptions presenting for the AMR in OTTO App. Report the collision to OTTO Motors Support at support@ottomotors.com 6. OTTO 100 V2.5 specifications This section provides an overview of the important elements of the OTTO 100 V2.5 autonomous mobile robot (AMR). OTTO 100 V2.5...
Page 21: Size And Weight
OTTO 100 V2.5 IMPORTANT Some of the following specifications are dependent on software, AMR, and/or safety configurations. 6.1. Size and weight Component Specification Dimensions (L x W x H) 740 x 550 x 308 mm (29.1 x 21.7 x 12.1 in)
Page 22: Battery And Power System
OTTO 100 V2.5 6.3. Battery and power system Component Specification Battery charge options Autonomous opportunity charging (default) Manual charging Battery chemistry Lithium Iron Phosphate Battery capacity 35 Ah Battery voltage 26.4 VDC nominal (28.8 VDC maximum) Maximum charge rate 98 A Battery dimensions (L x W x H) 197 x 132 x 179.5 mm (7.8 x 5.2 x 7.1 in)
Page 23: Operating Environment
OTTO 100 V2.5 6.6. Operating environment Component Specification Autonomous mode maximum 0.7° (1 %) floor slope Floor obstacle maximums Obstacle height: 6 mm (0.25 in) Floor gap: 13 mm (0.5 in) Operating speed may need to be limited to achieve safe traversal of these obstacles with a payload.
Page 24: Components Overview
OTTO 100 V2.5 7. Components overview The components overview is intended to familiarize users with the separate product components. 7.1. Components Integrated lift Light pipe LiDAR safety scanner LiDAR cavity OTTO 100 V2.5 OMM-000081-G...
Page 25: Integrated Lift
WARNING PINCH HAZARD! Keep objects and body parts away from pinch points. The OTTO 100 V2.5 is equipped with an internal lift capable of lifting payloads up to a maximum weight of: 150 kg (331 lbs) The top section of the robot above the LiDAR cavity can be raised to lift a payload or expose the charge contacts.
Page 26: Charge Contacts
OTTO 100 V2.5 7.3. Charge contacts The OTTO 100 V2.5 is equipped with charge contacts that are used when the AMR charges at the OTTO 100 Fast Charger. Note the location of the charge contact wear notch. If the notch is no longer visible, the charge contacts must be replaced.
Page 27: Power Button
The Power button is used to recover the robot from an unknown state. Momentarily pressing the Power button will boot up or shut down the robot or it can be held for 10 seconds to reset all electronics within the robot. OTTO 100 V2.5 rear buttons/input/output Ethernet connection Power button...
Page 28: Otto 100 V2.5 Rear Buttons/Input/Output
Manual charge port 7.9. 3D perception camera The OTTO 100 V2.5 is equipped with a 3D perception camera so that the operation of the robot can be monitored for diagnostic purposes. The camera is used in autonomous mode to avoid overhanging obstacles in newer software versions.
Page 29: Safety Lidar And Lidar Cavity
OTTO 100 V2.5 7.10. Safety LiDAR and LiDAR cavity The OTTO 100 V2.5 robot uses a LiDAR (Light Detection and Ranging) safety system to detect obstacles, prevent collisions, and localize in the environment. The LiDAR is connected directly to the drive system to help avoid collisions, preventing the robot from moving if there is an obstacle in the LiDAR field.
Page 30 OTTO 100 V2.5 Name Description Visual indication Reversing The AMR is reversing. Rear solid dull white in direction of travel Front solid red with dull white Turning The AMR is turning. Side blinking yellow in turn direction About to move...
Page 31 OTTO 100 V2.5 Name Description Visual indication Hazard The AMR is entering what it considers a Front solid dull white narrow Rear solid red pathway. Safety fields Blinking yellow stripes are reduced in size. WARNING CRUSH HAZARD! Pedestrians should be aware of hazard mode or docking mode audio-visual indications.
Page 32: Optical Rear Sensor
OTTO 100 V2.5 Name Description Visual indication Blocked The AMR is blocked from proceeding on Front flashing yellow its planned path. Rear solid red Safety stop The AMR has entered a safety stop Corners flashing red state. Emergency The AMR has...
Page 33: Otto 100 V2.5 Rear Buttons/Input/Output
OTTO 100 V2.5 OTTO 100 V2.5 rear buttons/input/output Ethernet connection Power button Safety Reset button Manual charge port 7.14. Circuit breakers and lock-out/tag-out The circuit breakers allow users to fully disconnect the battery from the OTTO 100 robot. The lock-out/tag-out pin drops into the LiDAR cavity to hold the breakers in the open position. The top breaker protects the drive and lift motors while the bottom breaker is the main battery power.
Page 34 OTTO 100 V2.5 • OTTO 100 • Wooden placeholders (2 x 2x4 wood pieces) • Ramp (wooden plank) • Lens wipes What to look for • Circles in marker around crate which define placement of screws • Wooden placeholders (two 2x4’s) overtop product keeps product secure from rising Unscrew crate screws and open crate.
Page 35: Basic Usage
OTTO 100 V2.5 Push and carefully slide the AMR down the ramp to remove it from the crate. 9. Basic usage This section describes the operation of the product. Prior to using the robot, the surrounding area must be approved for autonomous navigation by an OTTO representative.
Page 36: Starting Up
[35]. Press the Power button. The light pipe will indicate that the robot is starting up. The OTTO 100 V2.5 AMR will indicate an emergency stop state. Twist the Emergency Stop button in either direction. Press the Safety Reset button.
Page 37: Manually Charging The Amr
Move the AMR. Make sure to position it on level ground to prevent it from rolling. The OTTO 100 V2.5 has a robust structure that allows it to be picked up with the use of lifting machinery such as a forklift.
Page 38: Storing The Amr
OTTO 100 V2.5 The lifting equipment and straps used must be rated to the OTTO 100 V2.5's weight of: 107 kg (236 lbs) 9.6. Storing the AMR Before storing the AMR for an extended period of time (greater than two days), ensure the environmental requirements are met according to the system specifications.
Page 39: Connecting A Robot To A Network
OTTO 100 V2.5 9.8. Connecting a robot to a network Robots must be connected to a network to truly take advantage of the robot's autonomous capabilities. OTTO robots come with 2.4 GHz wireless frequency disabled but OTTO robots can support both 2.4 GHz and 5 GHz wireless frequencies.
Page 40: Adding A Robot To A Fleet
OTTO 100 V2.5 To use a Dynamic IP address assigned by the network, select Dynamic IP from the IP Type menu, and select Apply. Select Save and Restart Network. Restart the robot. 9.9. Adding a robot to a fleet To add a robot to the fleet, a computer must be connected to the OTTO autonomous mobile robot (AMR) and the robot must be connected to the network.
Page 41: Launching Otto App By Hostname
OTTO 100 V2.5 If managing a fleet of robots using OTTO Fleet Manager, use OTTO App to record a facility map, which can then be exported and uploaded to OTTO Fleet Manager for advanced editing and use by a fleet of robots.
Page 42: Robot Driving Modes
OTTO 100 V2.5 Robot driving modes There are several driving modes for each robot: autonomous, remote (drive assist on/off), and manual mode. The table below explains how each driving mode works. Driving mode Definition Autonomous In autonomous mode, the robot can drive to a set destination and perform movements between targeted mode [43] locations without remote controls or teleoperation input to maneuver it.
Page 43 OTTO 100 V2.5 Select Drive Mode Select Settings Select the Manual toggle to activate remote mode. A white joystick will appear. IMPORTANT If Drive Assist is enabled and a robot has no current goal, the Drive Mode toggle will display Assisted mode instead of Manual mode. If Drive Assist is enabled and the robot has an existing goal, the Drive Mode toggle will put the robot into remote mode,...
Page 44 OTTO 100 V2.5 IMPORTANT Confirm that the localization of the AMR on the map is correct before engaging Autonomous Mode. Failure to do so could result in the AMR entering Exclusion Zones or ignoring map features, potentially resulting in damaging the AMR and/or property.
Page 45: Controlling An Amr-Integrated Lift In Remote Mode
OTTO 100 V2.5 To send the AMR on its way, select Go. To stop the AMR at any time, select Stop. Driving using Endpoints IMPORTANT Confirm that the localization of the AMR on the map is correct before engaging Autonomous Mode. Failure to do so could result in the AMR entering Exclusion Zones or ignoring map features, potentially resulting in damaging the AMR and/or property.
Page 46: Preventative Maintenance
OTTO 100 V2.5 Note that this control is only available for robots with an integrated lift. 10. Preventative maintenance WARNING • SHOCK HAZARD! Always perform the lock-out/tag-out procedure at the facility or on the product before inspecting, servicing, cleaning, removing components, or opening any enclosure.
Page 47: Weekly Preventative Maintenance
OTTO 100 V2.5 Component Weekly 3 months 36 months Visually inspect the charge contacts for damage or debris Check the castors for damage or debris Check the drive wheels for damage or excessive wear Contact OTTO to check battery health 10.2. Weekly preventative maintenance...
Page 48: Inspecting The Grounding Strap
Only use the attachments, accessories, tools, replacement parts, and cleaning products approved by OTTO. Calibrating the OTTO 100 V2.5 battery The function and health of the robot battery is monitored by a Battery Management Unit (BMU) which is internal to the battery pack itself.
Page 49 Typically battery cells should be within a range of 50 mV—if not, the OTTO 100 V2.5 robot’s battery may suddenly drop in SoC while operating or the robot may unexpectedly shut off.
Page 50 OTTO 100 V2.5 A robot's operation mode indicates to OTTO Fleet Manager whether or not that robot is available to be assigned a job. Robot operation modes can be changed individually or across multiple robots. In OTTO Fleet Manager, select Monitor > Fleet and select the Robots tab.
Page 51: Monthly Preventative Maintenance
10. If the battery voltage does not suddenly jump and the robot does not shut down unexpectedly during this time, the calibration was successful. If the OTTO 100 V2.5 robot continues to experience issues with battery performance after completing this calibration procedure, contact OTTO Motors Support for further direction.
Page 52: Battery Cell Balancing
OTTO 100 V2.5 Battery cell balancing The function and health of the robot battery is monitored by a Battery Management Unit (BMU) which is internal to the battery pack itself. Over the operating life of the robot, the voltage of individuals cells will begin to diverge from each other.
Page 53 OTTO 100 V2.5 • Select multiple robots using iii. Click Actions. Mode buttons and additional details about the selected robot are displayed. Select the desired mode. IMPORTANT If it's observed that after changing an AMR to Unavailable mode, system states remain (for example, Endpoint ownership), toggle the AMR mode to Available, then back to Unavailable.
Page 54 OTTO 100 V2.5 Robot mode Description Manual The robot can only be driven manually using either physical controls or OTTO App. Payload status and other data is not cleared when a robot is put into manual mode. CAUTION • IMPACT HAZARD! Always maintain a safe distance from an AMR in operation.
Page 55: 3-Month Preventative Maintenance
Inspecting charge contacts Charge contacts The OTTO 100 V2.5 is equipped with charge contacts that are used when the AMR charges at the OTTO 100 Fast Charger. Note the location of the charge contact wear notch. If the notch is no longer visible, the charge contacts must be replaced.
Page 56: Inspecting The Wheels And Casters
Using the 6 mm Hex key, turn the lift motor clockwise to raise the lift of the robot. Raise the lift until both charge contacts are exposed. Inspect the wear notch on the OTTO 100 V2.5 charge contacts. If the notch is no longer visible, the charge contacts must be replaced.
Page 57 OTTO 100 V2.5 Along with another person, lift the opposite side of the AMR so that its side is now on the wooden planks. One person must keep the AMR stable and prevent it from falling over. Visually inspect the wheels.
Page 58: 36-Month Preventative Maintenance
Perform the following tasks at least once every 36 months. Battery health check The OTTO 100 V2.5 autonomous mobile robot battery is expected to last for at least 36 months of continuous operation. The actual lifetime experienced will vary greatly depending on the usage and operating environment.
Page 59 OTTO 100 V2.5 State Action AMR is making a If the sound is coming from the bottom of the AMR, check the casters and drive wheels to ensure no debris or loud or unusual object is jammed in the wheel cavities or the wheels.